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Idex PULSAFEEDER MPC Installation, Operation & Maintenance Manual

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Installation, Operation &
Maintenance
Manual
BULLETIN No. IOM-MPC-0104-F
Manufacturers of Quality Pumps,
Controls and Systems
Engineered Pump Operations
2883 Brighton-Henrietta Townline Road
Rochester, New York 14623
Telephone: (585) 292-8000 Fax: (585) 424-5619
http://www.pulsa.com
pulsa@idexcorp.com

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  • Page 1 Installation, Operation & Maintenance Manual BULLETIN No. IOM-MPC-0104-F Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623 Manufacturers of Quality Pumps, Telephone: (585) 292-8000 Fax: (585) 424-5619 Controls and Systems http://www.pulsa.com pulsa@idexcorp.com...
  • Page 2 Pulsafeeder personnel. Parts returned for warranty consideration that test satisfactorily, will be sent back to the originator via freight collect. Any field modifications will void the Pulsafeeder MPC warranty. Out-of-warranty repairs will be subject to Pulsafeeder's standard bench fees and testing costs associated with replacement components.

  • Page 3: Table Of Contents

    Table of Contents 1. I ..........................1 NTRODUCTION Description..........................1 MPC Standard Features......................2 Options..........................2 2. S ........................3 AFETY ONSIDERATIONS General Safety ........................3 Electrical Safety........................3 Mechanical Safety.......................3 Hydraulic Safety........................3 3. E ........................4 QUIPMENT NSPECTION 4. S .........................4 TORAGE NSTRUCTIONS Short Term (0 - 12 months)....................4 Long Term (12 months or more) ..................4 5.
  • Page 4 Conventions For the remainder of this bulletin, the following Conventions are in effect. WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT AY CLOSE ATTENTION TO ANY WARNING Notes are general information meant to make operating the equipment easier. Tips have been included within this bulletin to help the operator run the equipment in the most efficient manner possible.

  • Page 5: Introduction

    1. Introduction The Metering Pump Controller (MPC) is a microprocessor based motor speed control device, for use with Pulsafeeder mechanical and hydraulic diaphragm metering pumps. It has been designed for simplicity, yet still has many advanced features that allow the MPC to operate in a wide variety of environments and applications.

  • Page 6: Mpc Standard Features

    MPC Standard Features • Remote keypad and display for ease of operation • Display pump flow in GPH, LPH, Strokes per Minute, or % of full pump flow • One 4-20 mA analog input signal for flow control • One 4-20 mA analog output signal for flow feedback •...

  • Page 7: Safety Considerations

    2. Safety Considerations • Read and understand all related instructions and documentation before attempting to install or maintain this equipment • Observe all special instructions, notes, and cautions. • Act with care and exercise good common sense and judgment during all installation, adjustment, and maintenance procedures.

  • Page 8: Equipment Inspection

    3. Equipment Inspection When you receive your order, check all equipment for: • Completeness against the shipping document / purchase order • For any evidence of shipping damage. Shortages or damage should be reported immediately to the carrier and your Pulsafeeder Representative. 4.

  • Page 9: Installation And Wiring

    5. Installation and Wiring Location Review the Safety section (pg 3) prior to installing the MPC. It contains information required to properly install and operate the MPC in an industrial environment. The site selected for the installation of your MPC is largely dependent on that of the metering pump. Review the Installation, Operation, and Maintenance manual provided with your metering pump.

  • Page 10: Installation Notes

    VOID LOCATIONS WHERE THE WOULD BE SUBJECTED TO EXTREME COLD OR HEAT 40 ° C (104 ° 0° C (32° F LESS THAN ELSIUS AHRENHEIT OR GREATER THAN ELSIUS AHRENHEIT OR DIRECT SUNLIGHT AILURE TO OBSERVE THIS WARNING COULD DAMAGE AND VOID ITS WARRANTY Installation Notes The MPC is a microprocessor-based controller that uses electro-static sensitive CMOS components.
  • Page 11 5.3.1 Controller Layout The design of the MPC incorporates all control circuitry onto one easily accessed circuit board. This board is located on the inside of the main controller cover. Gain access to this board by removing the 10 bolts and gently allowing the cover to hinge downwards. SE CARE NOT TO PULL ON OR ATTEMPT TO COMPLETELY SEPARATE THE COVER FROM THE UNIT AS THE ELECTRICAL CONNECTIONS CAN BE DAMAGED...

  • Page 12: Power Wiring Information

    5.3.2 Power Wiring Information • Verify the correct supply voltage (115VAC or 230VAC) with the nameplate affixed to your MPC. Ensure that your supply voltage matches the MPC configuration. • Wires should be routed within the enclosure in a manner that maintains separation between high voltage and low voltage conductors.
  • Page 13 5.3.3 Power Wiring Diagram MPC Drive Terminal 120 V operation 240 V operation Line Line L2 / N Neutral Line Earth Ground Ground Table 2 – AC Drive Terminals LINE1 LINE2 / NEUTRAL EARTH GROUND Figure 3 – AC Power Connections Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor.

  • Page 14: Input/Output Signal Wiring

    5.3.4 Input/Output Signal Wiring Signal wiring is routed through the two unused conduit openings at the side of the MPC. All input/output signals are connected to the terminal strips at the edge of the MPC circuit board. Use caution to observe proper wire location and signal polarity.

  • Page 15: Check Wiring And Close Access Cover

    Digital output signals can drive devices such as relays or indicator lamps. 24 VDC power must be supplied from an external source. Each output has a maximum current capability of 500 mA. Figure 5 – Sample Digital Output Connections Check Wiring and Close Access Cover Double-check all of your electrical connections.

  • Page 16: Start Up And Operation

    6. Start Up and Operation Overview Once all electrical connections have been made, your MPC is ready for Start-up. The following sections detail the procedures required to complete the MPC start up. HEN POWER IS SUPPLIED TO THE UNIT LINE VOLTAGE IS PRESENT WITHIN THE OFF.

  • Page 17: Confirm Display And Keypad Functionality

    Confirm Display and Keypad Functionality The example display messages are shown in English for demonstration purposes. If an alternate language has been set, the text is displayed as a translation of the English version. Now that you have confirmed that the MPC is receiving power, it is necessary to confirm that the display and keypad are functioning properly.

  • Page 18: Factory Re-Initialization

    Factory Re-Initialization Factory Re-initialization is typically not required. When re-initializing your MPC, all of the system settings and calibration information will be overwritten by the original factory default settings. The controller must be re-configured and re-calibrated to your specifications. A Factory Re-initialization should be performed only if there is reason to believe that the internal MPC memory has become corrupted.

  • Page 19: Input/Output Setup

    7. Input/Output Setup Use the “DIGITAL I/O” menu to activate the functions required for the intended application. Users may also reference Section 12 – Menu Maps for additional configuration assistance Analog Input Setup Use the “ANALOG I/O” menu to activate the analog input signal function. The menu can be used to set the analog input to either ACTIVE or INACTIVE.

  • Page 20: Calibrations

    8. Calibrations Pump Flow Calibration Your MPC is factory calibrated at rated flow and pressure. Nevertheless, you should always perform a calibration with the MPC installed in your system. This will provide the most accurate flow display. The only item required to calibrate your MPC is a means to measure the flow of the pump (i.e., calibration column, graduated cylinder, etc.).
  • Page 21 8.1.1 To Start Calibration 1. The starting display will be: S E T P T X X . X X X F L O W X X . X X X 2. Press the MENU key - M E N U - C A L I B R A T I O N 3.
  • Page 22 8.1.2 Volume Method S E T S T R O K E T O 5 0 % E N T E R T O S T A R T 1. Manually adjust the stroke length of the pump to 50% 2.
  • Page 23 8.1.3 Flow Method S E T S T R O K E 5 0 % F L O W = 0 . 0 0 0 0 G P H 1. You do not have to adjust the actual stroke setting of the pump 2.

  • Page 24: Analog Input Calibration

    Analog Input Calibration If you are not using the 4-20mA input to the MPC for control, skip this section. To calibrate the Input Current you must first correctly wire an external signal source. Refer to Section 5 – Installation: Low Voltage Input Connections, Analog Input.
  • Page 25 11. Press the ENTER key M A X S E T P T X . X X M A S P E E D 1 0 0 . 0 % (The mA value will be equal to your input signal level) (The speed value is the setting the MPC will use for this signal value) 12.

  • Page 26: Analog Output Calibration

    Analog Output Calibration 1. The starting display will be: S E T P T X X . X X X F L O W X X . X X X 2. Press the MENU key - M E N U - C A L I B R A T I O N 3.

  • Page 27: Display Contrast Adjustment

    Display Contrast Adjustment Should adjustment of the contrast level of the display become necessary, use the following procedure while in the normal operating mode. To increase contrast, press and hold at the same time. To decrease contrast, press and hold at the same time.

  • Page 28: Alarm And Error Messages

    9. Alarm and Error Messages If a fatal error has occurred while in Operational Mode, the error will flash on the screen and the Red LED lamp will also flash. The menus can still be accessed by holding down the menu key. This allows the user to try and fix the source of the error if possible.
  • Page 29 NON-FATAL ERRORS: The pump and controller can still be run while these conditions exist. The Red LED will flash, however no message will flash on the screen. The Red LED will stop flashing once the error condition has been corrected. ALARM MPC does not receive valid indication from the stroke STROKE SENSOR...

  • Page 30: Extending Your Hand-Held Controller

    10. Extending your Hand-Held Controller The hand-held controller for your MPC can be placed as far as 1000 feet from the pump. It is recommended that all calibrations be completed before the cable is lengthened, as these tasks are easier when the pump and hand-held controller are close to each other.

  • Page 31: Removal And Connection Of The Cable From The Base Unit

    10.3 Removal and Connection of the Cable from the Base Unit: Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor. Capacitors retain a charge even after power is removed from the controller. 1. Remove the 10 screws that are securing the cover to the side of the main unit. 2.
  • Page 32 BLACK/RED GREEN BLACK/GREEN WHITE BLACK/WHITE Figure 5a – Handheld Remote Wiring TAPE END TAPE SHIELD BLK/GRN AN00446-006 Figure 5b – Wire Preparation Detail, Base Unit End...
  • Page 33 Figure 6 – Handheld Remote...

  • Page 34: Specifications

    11. Specifications Turndown: Up to 1000:1 with a steady state accuracy of +/- 2 % (added to pump accuracy rating) 3:1 with a steady state accuracy of +/- 1 % (added to pump accuracy rating) Operation mode: AC motor speed control with speed and stroke length feedback Manual stroke length control Recommended Minimum Wiring and Circuit Breaker 120 VAC Operation...
  • Page 35 Control Outputs Wiring Specification / Description J23 pins 5-6 4-20mA output for pump flow indication Analog Out #1 Max voltage out 12 Volts; Max current out 30mA; Max load resistance 300 Ohm Internally protected with resetable fuse J23 pins 1-4 Transistor-based output, various functions * Digital Out #1 Digital Out #2...

  • Page 36: Menu Maps

    12. Menu Maps Pulsafeeder, Inc. FW XX.XX/XX.XX Pump Serial Num: XXXXX MPC Part Number: MPCXXXXXXX-XXXX SETPT: 0.00GPH SETPT: 0.0 % SETPT: 0.00SPM SETPT: 0.0 % FLOW: 0.0 % SPEED: 0.00SPM SPEED: 0.0 % FLOW: 0.00GPH STROKE SET TO & XXX.X% -MENU- CALIBRATION CALIBRATION...
  • Page 37 -MENU- ANALOG I/O ANALOG INPUT #1 ANALOG I/O ANALOG INPUT #1 INACTIVE ANALOG INPUT #1 ANALOG INPUT #1 <INACTIVE> <ACTIVE> ANALOG INPUT #1 ANALOG INPUT #1 INACTIVE ACTIVE -MENU- DIGITAL I/O SIGNAL PURPOSE DIGITAL I/O DIGITAL INPUT #1 INACTIVE DIGITAL I/O SIGNAL PURPOSE SIGNAL PURPOSE SIGNAL PURPOSE...

  • Page 38: Factory Default Values

    13. Factory Default Values Parameter Factory Set Value Digital Input #1 INACTIVE, normally closed Digital Input #2 INACTIVE, normally closed Analog Input #1 INACTIVE Analog Input #2 NOT AVAILABLE this revision Digital Output #1 STROKE Indication, normally closed Digital Output #2 AUTO/MANUAL Indication, normally closed Digital Output #3 Alarm Indication, normally closed...

  • Page 39: Troubleshooting Guide

    16. Troubleshooting Guide Problem Potential Cause Solution DISPLAY No Display No power supplied. Check power source. plug & circuit breaker Back-lighting Supply power wired incorrectly. Check wiring. Supply power outside of specification. Check voltage/frequency against specification. No Text on Contrast out of adjustment. Adjust as per section 8.4 Display Software did not initiate properly.

  • Page 40: Spare Parts

    17. Spare Parts User replaceable parts for the MPC. Pulsafeeder P/N Description W770401-188 Housing cover bolt W774030-188 Housing cover washer NP460056-000 Housing cover gasket NP530091-000 ½” wiring liquidtight connector NP530137-000 ¼” wiring liquidtight connector NP530511-006 Hand-held unit (complete) NP140070-000 Hand-held unit angle-mount bracket NP140066-PVC Hand-held unit “snap-in”...
  • Page 42 BULLETIN No. IOM-MPC-0104-F Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623 Telephone: (585) 292-8000 Fax: (585) 424-5619 http: //www.pulsa.com pulsa@idexcorp.com...

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